Method of producing a bunch for manufacturing cigars,cigarillos or the like



United States Patent Dieter Neuber Folkungevagen l0, Jakobsberg, Sweden [21] Appl. No 701,270

[72] Inventor [22] Filed Jan. 29, 1968 [45] Patented Nov. 10, I970 [32] Priority May 18, 1967 [3 3 Sweden [54] METHOD OF PRODUCING A BUNCH FOR MANUFACTURING CIGARS, CIGARILLOS OR THE LIKE 1 Claim. 1 Drawing Fig.

[52] 11.8. CI. 131/20, 131/79, 131/133 [51] lnt.Cl A24c 01/16 [50] Field ofSeareh 131/79, 14, 17. 15,12,13, 79, 201A), 140-144 [56] References Cited UNITED STATES PATENTS 1,716,250 6/1929 Thiele l3l/12X 2,158,928 5/1939 Deich 131/79X 3,223,090 12/1965 Strubeletal... 131/140 3,378,015 4/1968 Heipmann..... l3l/20(A)UX 3,404,690 10/1968 Moshyetal. 131 140 Primary ExaminerMelvin D. Rein Attorney-Sughrue, Rothwell, Zinn and MacPeak ABSTRACT: The purpose of the invention is to provide an improved method of producing a novel cigar bunch. Conventional bunches comprise a batch of filler tobacco wound in a binder of natural tobacco or reconstituted tobacco. The winding process is time consuming and therefore the main object is to provide a method of making a bunch without a binder and in which the filler tobacco leaf parts are bound to one another so that the bunch maintains its shape and can be overrolled in a cigar machine and provided with a wrapper. According to the new method the individual tobacco leaves of the filler are provided with at least randomly distributed spots of a wet binding agent which is solidified so that the tobacco leaves of the bunch formed adhere to one another or are supported by a matrix constituted by the solidified binding agent. Preferably, the binding agent comprises water which has been frozen.

In conventional cigar manufacturing processes a hunch is produced by wrapping a filler tobacco in a binder, after which the bunch is provided with a wrapper. ln present day manufacture this method yields only 12-20 cigars per minute per machine, and the costs of manufacture are high. Attempts have been made to increase the production rate and to lower the costs by, inter alia, manufacturing single-leaf cigars; wherein the filler is wound direct in a wrapper, which is wound helically, or by a wrapper which is attached in the same manner as a cigarette paper, i.e. by glueing along a longitudinal edge thereof. The cigars etc. are mostly produced on modified cigarette rod machine. lt is true that the production rate is high, but the method produces cigars which are substantially cylindrical in shape, and of which one or both ends must be moulded into the desired shape,'whereby the true production rate per machine per unit of time is considerably reduced, and the necessary forming apparatus cause production costs to rise.

Attempts have been made to increase the production efficiency and to lower the costs of manufacture by producinga self-supporting bunch, i.e. an unwrapped bunch. According to this method powdered and shredded tobacco is mixed with a foaming binding agent, whereafter the mixture is formed into a bunch which is dried; whereby the binding agent foams and the compact mass becomes porous. However, the obtained porous product contains such a quantity of substances unrelated to the tobacco that the smoking thereof is impaired, and, further, the finished cigar is not porous enough to permit air to pass therethrough to the desired extent.

The object of the present invention is to provide a method of producing an unwrapped bunch which is completely free from deleterious binding agents or only contains insignificant amounts of such, but which in despite of this is suitable for use in conventional cigar machines and which can be provided with a wrapper in the form of for example reconstituted tobacco.

The novel method of producing a bunch comprising threshed or long filler tobacco and binding agent, for the manufacture of a cigar, cigarillo or a similar tobacco product is characterized in that the leaf portions of the filler tobacco are supplied spotwise or layerwise in at least the outer portion with a wet binding agent, and that the binding agent thereafter is solidified while keeping the bunch filler tobacco in a predetermined shape.

According to the invention the binding agent may be water, which is frozen after or duringthe forming of the bunch. The ice matrix thus obtained maintains the shape of the tiller tobacco until a wrapper is applied to the bunch.

'Further, the binding agent may comprise wet, finely ground tobacco or be an aqueous polysaccharide solution.

However, since the binding agent as such is not a critical feature any suitable innocuous binding agent can be used. The aforementioned binding agents are, however, to be preferred.

When applying the novel method only an insignificant amount of binding agent need be addedto the portions of the tobacco leaves, thus retaining completely theappearance and flavour o ftthe tobacco, and eliminating the risk of the bunch becoming impermeable to air. A particularly good result is obtained when the binding agent is comprised of frozen water, since all traces of binding agent disappear in the finished cigar.

The invention will now be described with reference to the accompanying drawing, which very schematically illustrates an embodiment of an equipment for manufacturing the novel bunches.

The drawing shows a driven conveyor belt or chain 1, which is provided with mould halves 2. Each mould half 2 is provided with an inner cavity corresponding to a bunch cut along its longitudinal axis. Thebelt 1 passes over rollers 3 and 4, of which 3 is driven in the direction of the arrow. Located below and at a distance from the lower portion of the belt 1 is a second belt 5, driven synchronously with the first belt, and

which is provided with mould halves 6 of the same type as themouldhalves 2. 'Thebelt 5 passes over rollers 7 and 8, of which the'roller 7 is driven in the direction of the arrow. The distance between the lower part of the belt 2 and the upper part of the belt 5 is somewhat less than the height of two superimposed mould halves 2, 6. The lower part of the belt 1 is passed further over two.bridle rollers 9, 10, in order to increase the inlet and outlet gap between the belt I and the belt 5. The figure also shows a filler portioning means 11., by means 'of which a filler portion 12 of the shredded or unshredded tobacco is transferred to a mould half present under the'portioning means 11. As can be seen from the drawing, a mouldhalf 6 filled with a filler portion 12 is caused to cooperate with a mould half 2 in the inlet gap between the belt 1 and the belt 5. The mould halves 2, 6 are pressed together during movement of the belt 1 and the belt 5; thereby shaping the filler portion 12 in the desired manner.

lt is assumed that at this stage the tiller tobacco is moistened with water or an aqueous solution by means (not shown) before or during the portioning step, in that the tobacco is passed, for instance, through a curtain of water droplets and that the water content of the tobacco is thus increased to at least 30 percent by weight and preferably to approximately 35 percent by weight, or more. The moistened tobacco filler is carried enclosed within two mould halves 2, 6 into a freezer 13, in which the water in the tobacco freezes and forms an ice matrix, which retains the tiller in the shape obtained in the two mould halves during the shaping step. The frozen bunch is discharged in the direction of arrow 14 for further treatment; for instance in a conventional cigar manufacturing machine, wherein it is provided with a wrapper. The bunch may, of course, also be stored in a refrigerator for later use.

An analogous method can be applied by substituting the water, which in frozen state forms the necessary binding agent, with a conventional binder, such as a carboxymethylcellulose dissolved in water or some other polysaccharide solution. This solution is suitably sprayed on the tiller tobacco prior to the portioning step.

It is also possible and suitable to use wet ground tobacco of the same type as is used for manufacturing strip tobacco as a binding agent, although the tobacco should be ground until it is at least partly gelatinated, to provide for better adhesion. This latter type of binding agent is equally as suitable from the aspect of flavour as frozen water, since it comprises pure tobacco without any other additive than water.

When using the last two mentioned types of binding agents the freezer 13 is replaced with a heating chamber, in which the binding agent is dried and converted to solid state.

Other suitable binding agents are pressure-sensitive adhesives, i.e. adhesives of the type which comprise microscopic balls containing a binding agent; the balls rupturing when subjected to pressure, thus releasing the binding agent. The balls are suitably suspended in water and the suspension is applied in a suitable manner, e.g. by spraying on the tiller tobacco. When a filler portion is compressed, e.g. by the above described mould halves, the pressure is highest in the outer layer of the bunch and the balls rupture in this region,

whereby after drying the bunch is held together by an external shell of portions of tobacco leaf glued together.

The binding agent need not be applied in the form of a continuous layer on each portion of tobacco leaf, but may be applied spotwise'if so required; whereby the content of binding agent can be kept to a minimum. Neither it is necessary to apply the binding agent before portioning the tobacco into a mould half 6. If desired the binding agent can be applied through channels in the mould halves, whereby only the outer layer of filler tobacco need be moistened. After being frozen or dried, which ever the case may be, this layer forms a stable shell, which retains the desired shape of the bunch.

A bunch produced in this manner can be provided. with a binder in the form of an applied and dried mass of tobacco of tobacco.

I claim:

freezing the enclosed material in such wise that the frozen water acts as a temporary binder for the tobacco pieces retaining them in the shape of the mold when released therefrom, and finally wrapping this molded unit while frozen. 

